On-board electrical power generator operated by vibration or compressed air

• US 5,945,749 A
• Filed: 06/10/1998
• Issued: 08/31/1999
• Est. Priority Date: 06/10/1998
• Status: Expired due to Fees

• Current Assignee: Westinghouse Air Brake Technologies Corporation
• Original Assignee: Westinghouse Air Brake Technologies Corporation
• Inventors: Li, Wei
• Primary Examiner(s): Ramirez, Nestor
• Assistant Examiner(s): NGUYEN, TRAN N
• Application Number:
  US09/095,082
• Time in Patent Office: 447 Days
• Field of Search: 310/12, 310/13, 310/15, 310/17, 310/20, 310/21, 310/27, 310/28, 310/30, 310/34, 310/35, 310/36, 310/81, 290/53, 290/42
• US Class Current: 310/15
• CPC Class Codes: H02K 7/1884 structurally associated with free piston engines

Abstract

The invention provides an on-board electrical power generator for application on railway cars as a power supply for Electronically Controlled Pneumatic (ECP) brake equipment and other on-board electronic devices, such as an end of train unit. The generator unit can by operated by vehicle vibration when the train is moving, or by fluid pressure from the brake line when the train is stopped. The generator unit has a magnetic piston surrounded by a coil and is engaged on either end by diaphragm-spring combinations. This arrangement creates a mass-spring system in which the magnetic piston vibrates under external excitation. The oscillation of the magnetic piston as a result of vehicle movement allows interaction between the magnetic piston and a coil and thus generates electrical voltage across the coil as a result of vibration. The diaphragms of the diaphragm-spring combinations create two sealed chambers on the first and second ends of the generator which allows the piston to be actuated by fluid pressure. Fluid pressure from a control valve alternately flows between the first chamber and the second chamber causing the piston to oscillate and thus create an electrical voltage across such coil and thereby generating electrical power.

Claims

1. An on-board electrical power generation system for generating electrical power on a railway vehicle, said on-board electrical power generation system comprising:

(a) a generator assembly, said generator assembly including;

(i) a housing member having a bore disposed along a longitudinal axis thereof;

(ii) a magnetic piston axially disposed for reciprocal movement within said bore of said housing member, said magnetic piston having a first end and a second end, said first end and said second end having a first rodlike member and a second rodlike member, respectively, extending outwardly substantially from a midpoint of a longitudinal axis extending through said magnetic piston, said first rodlike member having a first predetermined diameter and said second rodlike member having a second predetermined diameter;

(iii) a first diaphragm member disposed in said housing member, said first diaphragm member having a first central opening, said first central opening having a third predetermined diameter, said first diaphragm member engaging said first end of said magnetic piston with said first rodlike member of said magnetic piston extending through said first central opening;

(iv) a first cover secured to a first end of said housing member, said first cover including a first cylindrically shaped and generally hollow projection extending in an outwardly direction to accommodate longitudinal movement of said first rodlike member of said magnetic piston therein, said first cover further including a first chamber in fluid communication with said first generally hollow projection, said first chamber further being connected for fluid communication with a first source of fluid pressure, said first chamber being sealed by said first diaphragm member;

(v) a second diaphragm member disposed in said housing member, said second diaphragm member having a second central opening, said second central opening having a fourth predetermined diameter, said second diaphragm member engaging said second end of said magnetic piston with said second rodlike member of said magnetic piston extending through said second central opening;

(vi) a second cover secured to a second end of said housing member, said second cover including a second cylindrically shaped and generally hollow projection extending in an outwardly direction to accommodate longitudinal movement of said second rodlike member of said magnetic piston therein, said second cover further including a second chamber in fluid communication with said second generally hollow projection, said second chamber further being connected for fluid communication with a second source of fluid pressure, said second chamber being sealed by said second diaphragm member;

wherein fluid pressure in said second chamber is being exhausted when fluid pressure in said first chamber is being pressurized and fluid pressure in said first chamber is being exhausted when fluid pressure in said second chamber is being pressurized;

(vii) a first biasing means axially disposed within one of said first generally hollow projection and said first chamber and caged between an inner surface of said first cover and one of an end surface of said first rodlike member and said first diaphragm member for urging said magnetic piston in a first direction;

(viii) a second biasing means axially disposed within one of said second generally hollow projection and said second chamber and caged between an inner surface of said second cover and one of an end surface of said second rodlike member and said second diaphragm member for urging said magnetic piston in a second direction, said second direction being reciprocal to said first direction; and

(ix) an electric coil disposed within said housing member and disposed so as to enclose said magnetic piston whereby movement of said magnetic piston creates a voltage across said electric coil and thereby generating electrical power;

(b) a piston type control valve connectable to a source of fluid pressure and further in fluid communication with said first chamber in said first cover and said second chamber in said second cover of said generator assembly, said piston type control valve providing fluid pressure alternately to said first chamber in said first cover and said second chamber in said second cover of said generator assembly causing said magnetic piston to oscillate between said first diaphragm and first biasing means and said second diaphragm and said second biasing means; and

(c) a switching means for controlling such fluid pressure supply to said control valve, said switching means opening to permit fluid communication with said control valve when such railway car is stopped thereby causing said magnetic piston to oscillate by fluid pressure and closing to restrict fluid communication to said control valve when such railway car is moving thereby permitting said magnetic piston to oscillate between said first diaphragm and said first biasing means and said second diaphragm and said second biasing means by means of vehicle vibration.

2. An on-board electrical power generation system for generating electrical power on a railway vehicle, according to claim 1, wherein said magnetic piston is disposed in a generally vertical direction within said housing.

3. An on-board electrical power generation system for generating electrical power on a railway vehicle, according to claim 1, wherein said switching means for controlling such supply of fluid pressure to said control valve is a solenoid valve.

4. An on-board electrical power generation system for generating electrical power on a railway vehicle, according to claim 1, wherein said on-board electrical power generation system further includes a sensing means connected electrically to said switching means for controlling automatic switching between a fluid pressure mode of operation and a vibrational mode of operation.

5. An on-board electrical power generation system for generating electrical power on a railway vehicle, according to claim 4, wherein said second solenoid valve is energized when such railway car is in an empty condition, said solenoid valve having a restricted exhaust when energized.

6. An on-board electrical power generation system for generating electrical power on a railway vehicle, according to claim 1, wherein said switching means further includes a second solenoid valve which is in fluid communication with an exhaust port of said control valve, said second solenoid valve permitting said on-board electrical power generation system to be sensitive to changes in vibration because of empty conditions.

7. An on-board electrical power generation system for generating electrical power on a railway vehicle, according to claim 6, wherein said sensing means further includes a second sensor for discerning variations in load conditions.

8. An on-board electrical power generation system for generating electrical power on a railway vehicle, according to claim 1, wherein said fluid pressure is pneumatic.

9. An on-board electrical power generation system for generating electrical power on a railway vehicle, according to claim 1, wherein said first biasing means and said second biasing means in said generator unit are springs.

10. An electric power generator for generating electrical power on a railway vehicle, said electrical power generator comprising:

(a) a housing member having a bore disposed along a longitudinal axis thereof;

(b) a magnetic piston axially disposed for reciprocal movement within said bore of said housing member, said magnetic piston having a first end and a second end, said first end and said second end having a first rodlike member and a second rodlike member, respectively, extending outwardly substantially from a midpoint of a longitudinal axis extending through said magnetic piston, said first rodlike member having a first predetermined diameter and said second rodlike member having a second predetermined diameter;

(c) a first diaphragm member disposed in said housing member, said first diaphragm member having a first central opening, said first central opening having a third predetermined diameter, said first diaphragm member engaging said first end of said magnetic piston with said first rodlike member of said magnetic piston extending through said first central opening;

(d) a first cover secured to a first end of said housing member, said first cover including a first cylindrically shaped and generally hollow projection extending in an outwardly direction to accommodate longitudinal movement of said first rodlike member of said magnetic piston therein, said first cover further including a first chamber in fluid communication with said first generally hollow projection, said first chamber further being connected for fluid communication with a first source of fluid pressure, said first chamber being sealed by said first diaphragm member;

(e) a second diaphragm member disposed in said housing member, said second diaphragm member having a second central opening, said second central opening having a fourth predetermined diameter, said second diaphragm member engaging said second end of said magnetic piston with said second rodlike member of said magnetic piston extending through said second central opening;

(f) a second cover secured to a second end of said housing member, said second cover including a second cylindrically shaped and generally hollow projection extending in an outwardly direction to accommodate longitudinal movement of said second rodlike member of said magnetic piston therein, said second cover further including a second chamber in fluid communication with said second generally hollow projection, said second chamber further being connected for fluid communication with a second source of fluid pressure, said second chamber being sealed by said second diaphragm member;

wherein fluid pressure in said second chamber is being exhausted when said first chamber is being pressurized and fluid pressure in said first chamber is being exhausted when said second chamber is being pressurized;

(g) a first biasing means axially disposed within one of said first generally hollow projection and said first chamber and caged between an inner surface of said first cover and one of an end surface of said first rodlike member and said first diaphragm member for urging said magnetic piston in a first direction;

(h) a second biasing means axially disposed within one of said second generally hollow projection and said second chamber and caged between an inner surface of said second cover and one of an end surface of said second rodlike member and said second diaphragm member for urging said magnetic piston in a second direction, said second direction being reciprocal to said first direction; and

(i) an electric coil disposed within said housing member and positioned to encircle at least a predetermined portion of said magnetic piston whereby movement of said magnetic piston creates a voltage across said electric coil and thereby generating such electrical power.

11. An electric power generator for generating electrical power on a railway vehicle, according to claim 10, wherein said first biasing means and said second biasing means are springs.

12. An electric power generator for generating electrical power on a railway vehicle, according to claim 11, wherein said first biasing means is disposed around said first rodlike member at said first end of said magnetic piston, said first biasing means being caged between said first diaphragm member and an inner surface of said first cover, and said second biasing means is disposed around said second rodlike member at said second end of said magnetic piston, said second biasing means being caged between said second diaphragm member and an inner surface of said second cover.

13. An electric power generator for generating electrical power on a railway vehicle, according to claim 11, wherein said spring of said first biasing means and said spring of said second biasing means are substantially identical.

14. An electric power generator for generating electrical power on a railway vehicle, according to claim 10, wherein said fluid pressure is pneumatic.

15. An electric power generator for generating electrical power on a railway vehicle, according to claim 10, wherein said magnetic piston is disposed in a generally vertical direction within said housing during service.

16. An electric power generator for generating electrical power on a railway vehicle, according to claim 10, wherein said first predetermined diameter and said second predetermined diameter are substantially identical.

17. An electric power generator for generating electrical power on a railway vehicle, according to claim 10, wherein said third predetermined diameter and said fourth predetermined diameter are substantially identical.

18. An electric power generator for generating electrical power on a railway vehicle, said electrical power generator comprising:

(a) a housing member having a bore disposed along a longitudinal axis thereof;

(b) a magnetic piston axially disposed for reciprocal movement within said bore of said housing member, said magnetic piston having a first end and a second end, said first end and said second end having a first rodlike member and a second rodlike member, respectively, extending outwardly substantially from a midpoint of a longitudinal axis extending through said magnetic piston, said first rodlike member having a first predetermined diameter and said second rodlike member having a second predetermined diameter;

(c) a first diaphragm member disposed in said housing member, said first diaphragm member having a first central opening, said first central opening having a third predetermined diameter, said first diaphragm member engaging said first end of said magnetic piston with said first rodlike member of said magnetic piston extending through said first central opening;

(d) a first cover secured to a first end of said housing member, said first cover including a first cylindrically shaped and generally hollow projection extending in an outwardly direction to accommodate longitudinal movement of said first rodlike member of said magnetic piston therein, said first cover further including a first chamber in fluid communication with said first generally hollow projection, said first chamber further being connected for fluid communication with a first source of fluid pressure, said first chamber being sealed by said first diaphragm member;

(e) a second diaphragm member disposed in said housing member, said second diaphragm member having a second central opening, said second central opening having a fourth predetermined diameter, said second diaphragm member engaging said second end of said magnetic piston with said second rodlike member of said magnetic piston extending through said second central opening;

(f) a second cover secured to a second end of said housing member, said second cover including a second cylindrically shaped and generally hollow projection extending in an outwardly direction to accommodate longitudinal movement of said second rodlike member of said magnetic piston therein, said second cover further including a second chamber in fluid communication with said second generally hollow projection, said second chamber further being connected for fluid communication with a second source of fluid pressure, said second chamber being sealed by said second diaphragm member;

wherein fluid pressure in said second chamber is being exhausted when said first chamber is being pressurized and fluid pressure in said first chamber is being exhausted when said second chamber is being pressurized; and

(g) an electric coil disposed within said housing member and positioned to encircle at least a predetermined portion of said magnetic piston whereby movement of said magnetic piston creates a voltage across said electric coil and thereby generating such electrical power.

19. An electric power generator for generating electrical power on a railway vehicle, according to claim 18, wherein said generator further includes a first resistance means engagable with said magnetic piston and disposed within said first chamber for preventing contact between said magnetic piston and an inner surface of said first cover and a second resistance means engagable with said magnetic piston and disposed within said second chamber for preventing contact between said magnetic piston and an inner surface of said second cover.

20. An electric power generator for generating electrical power on a railway vehicle, according to claim 19, wherein said first resistance means and said second resistance means are springs.

21. An electric power generator for generating electrical power on a railway vehicle, according to claim 18, wherein said fluid pressure is pneumatic.

22. An electric power generator for generating electrical power on a railway vehicle, said electrical power generator comprising:

(a) a housing member having a bore disposed along a longitudinal axis thereof;

(b) a magnetic piston axially disposed for reciprocal movement within said bore of said housing member, said magnetic piston having a first end and a second end, said first end and said second end having a first rodlike member and a second rodlike member, respectively, extending outwardly substantially from a midpoint of a longitudinal axis extending through said magnetic piston, said first rodlike member having a first predetermined diameter and said second rodlike member having a second predetermined diameter;

(c) a first cover secured to a first end of said housing member, said first cover including a first cylindrically shaped and generally hollow projection extending in an outwardly direction to accommodate longitudinal movement of said first rodlike member of said magnetic piston therein, said first cover further including a first chamber in fluid communication with said first generally hollow projection;

(d) a second cover secured to a radially opposed second end of said housing member, said second cover including a second cylindrically shaped and generally hollow projection extending in an outwardly direction to accommodate longitudinal movement of said second rodlike member of said magnetic piston, said second cover further including a second chamber in fluid communication with said second generally hollow projection;

(e) a first biasing means axially disposed within one of said first generally hollow projection and said first chamber and caged between an inner surface of said first cover and one of an end surface of said first rodlike member and an end surface of said first end of said magnetic piston for urging said magnetic piston in a first direction;

(f) a second biasing means axially disposed within one of said second generally hollow projection and said second chamber and caged between an inner surface of said second cover and one of an end surface of said second rodlike member and an end surface of said second end of said magnetic piston for urging said magnetic piston in a second direction, said second direction being reciprocal to said first direction; and

(g) an electric coil disposed within said housing member and positioned to encircle at least a predetermined portion of said magnetic piston whereby movement of said magnetic piston creates a voltage across said electric coil and thereby generating such electrical power.

23. An electric power generator for generating electrical power on a railway vehicle, according to claim 22, wherein said first biasing means and said second biasing means are springs.

24. An electric power generator for generating electrical power on a railway vehicle, according to claim 23, wherein said first biasing means is disposed around at least a predetermined portion of said first rodlike member at said first end of said magnetic piston, said first biasing means being caged between an inner surface of said first cover and said first end of said magnetic piston, and said second biasing means is disposed around at least a predetermined portion of said second rodlike member at said second end of said magnetic piston, said second biasing means being caged between an inner surface of said second cover and said second end of said magnetic piston.

25. An electric power generator for generating electrical power on a railway vehicle, according to claim 22, wherein said magnetic piston is disposed in a generally vertical direction within said housing during service.

26. A control valve for use in a power generating system disposed on a railway vehicle, said control valve comprising:

(a) an elongated housing member having a predetermined shape;

(b) a cylindrically shaped bore formed through said housing member from a first end thereof to a second end thereof and along a longitudinal axis thereof;

(c) an inlet port formed through a side wall of said housing member closely adjacent said first end thereof, said inlet port being adapted to be connected to a source of fluid pressure and in fluid communication with said cylindrically shaped bore;

(d) an exhaust port formed through said side wall of said housing member substantially radially opposed to said inlet port and in fluid communication between said cylindrically shaped bore and atmosphere;

(e) an elongated cylindrically shaped bushing having an elongated cylindrically shaped bore disposed within said cylindrically shaped bore along said longitudinal axis of said housing member;

(f) a first elongated and arcuately shaped fluid communication passageway having a first predetermined length and a first predetermined depth formed in at least one of an inner surface of said housing member and an outer surface of said elongated cylindrically shaped bushing, said first elongated and arcuately shaped fluid communication passageway being disposed in fluid communication with said inlet port;

(g) a second elongated and arcuately shaped fluid communication passageway having a second predetermined length and a second predetermined depth formed in at least one of said inner surface of said housing member and said outer surface of said elongated cylindrically shaped bushing, said second elongated and arcuately shaped fluid communication passageway being disposed in fluid communication with said exhaust port;

(h) a third elongated and arcuately shaped fluid communication passageway having a third predetermined length and a third predetermined depth formed in at least one of said inner surface of said housing member and said outer surface of said elongated cylindrically shaped bushing, said third elongated and arcuately shaped fluid communication passageway disposed at a point beginning closely adjacent said first end of said housing member and a first end of said elongated cylindrically shaped bushing;

(i) a fourth elongated and arcuately shaped fluid communication passageway having a fourth predetermined length and a fourth predetermined depth formed in at least one of said inner surface of said housing member and said outer surface of said elongated cylindrically shaped bushing, said fourth elongated and arcuately shaped fluid communication passageway disposed at a point beginning closely adjacent said second end of said housing member and a second end of said elongated cylindrically shaped bushing;

(j) a first aperture having a first predetermined configuration formed through a sidewall of said elongated cylindrically shaped bushing substantially at a midpoint thereof, said first aperture in fluid communication with said first elongated and arcuately shaped fluid communication passageway and with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing;

(k) a second aperture having a second predetermined configuration formed through a sidewall of said elongated cylindrically shaped bushing substantially radially opposed to said first aperture and disposed closely adjacent said first end of said bushing, said second aperture in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing and with said second elongated and arcuately shaped fluid communication passageway;

(l) a third aperture having a third predetermined configuration formed through a sidewall of said elongated cylindrically shaped bushing substantially radially opposed to said first aperture and disposed closely adjacent said second end of said bushing, said third aperture in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing and with said second elongated and arcuately shaped fluid communication passageway;

(m) a fourth aperture having a fourth predetermined configuration formed through a sidewall of said elongated cylindrically shaped bushing disposed at a second end of said third elongated and arcuately shaped fluid communication passageway, said fourth aperture in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing and with said third elongated and arcuately shaped fluid communication passageway;

(n) a fifth aperture having a fifth predetermined configuration formed through a sidewall of said elongated cylindrically shaped bushing disposed at said point beginning closely adjacent said first end of said bushing of said third elongated and arcuately shaped fluid communication passageway, said fifth aperture in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing and with said third elongated and arcuately shaped fluid communication passageway;

(o) a sixth aperture having a sixth predetermined configuration formed through a sidewall of said elongated cylindrically shaped bushing disposed at a second end of said fourth elongated and arcuately shaped fluid communication passageway, said sixth aperture in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing and with said fourth elongated and arcuately shaped fluid communication passageway;

(p) a seventh aperture having a seventh predetermined configuration formed through a sidewall of said elongated cylindrically shaped bushing disposed at said point beginning closely adjacent said second end of said bushing of said fourth elongated and arcuately shaped fluid communication passageway, said seventh aperture in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing and with said fourth elongated and arcuately shaped fluid communication passageway;

(q) a piston having a fifth predetermined length disposed for reciprocal movement within said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing along a longitudinal axis thereof, said piston having a center portion having a sixth predetermined length, said center portion having a reduced diameter forming a first chamber between said center portion of said piston having a reduced diameter and said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing, said first chamber in fluid communication with said first aperture and one of said fourth aperture and said sixth aperture;

(r) a first cover secured to said first end of said elongated housing member;

(s) a first outlet port formed through said first cover, said first outlet port in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing;

(t) a second cover secured to said second end of said elongated housing member;

(u) a second outlet port formed through said second cover, said second outlet port in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing;

wherein such fluid pressure from such external source enters said control valve through said inlet port, such fluid pressure is communicated through said first elongated and arcuately shaped fluid communication passageway through said first aperture into said first chamber, such fluid pressure is communicated through one of said fourth aperture and said sixth aperture through one of said third and said fourth elongated and arcuately shaped fluid communication passageways to one of said fifth aperture and said seventh aperture where such fluid pressure returns to said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing, such fluid pressure exits from one of said first and said second outlet ports and builds up pressure behind one end of said piston forcing said piston to move toward an opposite end of said housing member until said piston has moved a sufficient distance to uncover one of said second aperture and said third aperture and close such other of said second aperture and said third aperture, while said first chamber of said piston has moved a sufficient distance so as to provide fluid communication to such one of said fourth aperture and said sixth aperture which was not previously in fluid communication with said first chamber, such fluid pressure, while exiting from such other one of said first outlet port and said second outlet port, now builds up pressure behind an opposite end of said piston causing said piston to move in a reciprocal direction.

27. A piston type control valve in an electrical power generation system disposed on a railway vehicle, according to claim 26, wherein said control valve further includes a first cushion disposed within said housing member between said first end of said bushing and said first cover and a second cushion disposed within said housing member between said second end of said bushing and said second cover, said first cushion having an eighth aperture in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing and with said first outlet port in said first cover and said second cushion having a ninth aperture in fluid communication with said elongated cylindrically shaped bore of said elongated cylindrically shaped bushing and with said second outlet port in said second cover.

28. A piston type control valve in an electrical power generation system disposed on a railway vehicle, according to claim 26, wherein said fluid pressure is pneumatic.