AU2005211554A1 - An electrical rail coupler assembly - Google Patents

Description

S&F Ref: 720824

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name and Address of Applicant: Actual Inventor(s): Address for Service: Invention Title: New Macey Pty Limited, an Australian company, ACN 089 494 646, of 3/19 Enterprise Drive, Tomago, New South Wales, 2322, Australia Laurence David Macey Spruson Ferguson St Martins Tower Level 31 Market Street Sydney NSW 2000 (CCN 3710000177) An electrical rail coupler assembly The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5845c AN ELECTRICAL RAIL COUPLER ASSEMBLY Field of the Invention The present invention relates to railway trains and in particular to electrical rail coupler assemblies connecting the electrical power and controls between train carriages.

Background of the Invention A railway train consists of a number of carriages releasably secured together by a carriage coupler assembly. That coupler assembly can include a rack or pinion (link and pin type couplers) retaining the carriages together during motion. Other types include automatic coupling assemblies which resemble a right handed fist, the jaw of the l0 couplings are opened and when the carriages come together the coupling is locked closed.

A lever lifts a locking key in either coupling to uncouple the carriages apart.

As railway trains have become more complicated, with electrical power and controls connecting one carriage to another, systems for coupling those power and control circuits have been needed. Those circuits typically allow remote control of the carriage doors, lighting, security systems and the like.

Existing electrical couplers are usually either cables or conduits with plugs at one end and hard wired at the other end. The plug end couples to a receptacle on the adjoining carriage. Where existing systems are adopted, it is also necessary to provide a parking or dummy receptacle to hold the jumper when carriages are disconnected.

Alternatively, it is possible to use receptacles at each end of the carriages and connect adjoining carriages with a double plugged jumper.

[R:\LIBLL] 6928.doc:gxt Electrical railway couplers typically fail because they are used in harsh environments where there are severe vibrations, changes in temperature, acidity and humidity. Water and dirt commonly enter onto the electrical contacts causing failure of the electrical circuits. Further, any coupler assembly must not be too heavy, bulky or difficult to fit otherwise operators will resort to hammers, levers and other tools to force parts together damaging sensitive componentary. Maintenance is also a significant issue in railway train systems and any assembly must be easy and cheap to maintain.

Existing systems based on plugs and receptacles are slow to disconnect and reconnect, particularly at night and during poor weather conditions. If they are left joined when the mechanical coupler between two carriages is released, significant damage can be caused to the electrical system because the cabling is stretched to breaking point as carriages are shunted. Looser jumpers can be lost, while if one end is disconnected and the other end left in place, the jumpers can be dragged along the ballast, smashing the electrical connectors or catching them in points or other obstructions.

Separate plugs and receptacles are bulky and the hanging catenaries of cables are vulnerable to shrapnel damage from flying ballast. Receptacle covers are often left open due to operator error, allowing further encrustation of electrical contacts with dirt, acidic and alkaline washing solutions, and water, snow and ice.

Object of the Invention It is an object of the present invention to overcome or ameliorate some of the disadvantages of the prior art, or at least to provide a useful alternative.

(R:\LIBLL] 6928.doc:gxt Summary of the Invention There is firstly disclosed herein an electrical rail coupler assembly to maintain in use electrical contact between adjacent railway carriages; said assembly including a pair of complimentary coupler sub-assemblies securable together in use to maintain said electrical contact therebetween; each said coupler sub-assembly including: a base to be fixed to a respective one of said carriages; a body attached to the base; at least one electrical plug portion to engage an electrical receptacle portion of the other sub-assembly so that the sub-assemblies when secured together are electrically connected; and wherein the electrical portions are moved, into electrical contact engagement by relative movement, in a predetermined direction by at least one of the bodies being movable in said direction relative to its associated base to provide for engagement and disengagement of said plug and receptacle portions; and securing means extending between the bodies to releasably secure the bodies together with the plug and receptacle portions in electrical contact.

Preferably, both said bodies are movable in said direction relative to their associated base.

Preferably, at least one said body includes positioning means to adjust the position of said body relative -to said base.

[R:\LIBLL] 16928.doc:gxt Preferably, said positioning means includes a pin extending through an aperture in said body and movable in said direction, said pin being fixed to said base.

Preferably, each said body includes an aperture to receive said electrical plug or receptacle portion.

Preferably, each said body includes a plurality of apertures for receipt of a plurality of electrical plug or receptacle portions.

Preferably, said securing means includes a locking pin extending normal from one said body for locking engagement with a complimentary aperture located in said other body.

Preferably, said locking pin includes a threaded portion.

Preferably, said locking pin includes a handle.

Preferably, each said electrical plug or receptacle portion is a sealed module.

Preferably, when said electrical plug and receptacle portions are in electrical contact engagement, the plug and receptacle portions are also in sealing engagement.

Preferably, each said electrical plug and receptacle portion includes a means of keying the plug and receptacle portion, so that the corresponding plug and receptacle portions are, in use, always mated.

Preferably, each plug and receptacle portion is individually removable and replacable without disturbing other plug and receptacle portions.

[R:\LIBLLJ 16928.doc:gxt Preferably, all plug and receptacle portions are electrically earthed to the body for safe operation.

Preferably, all plug and receptacle portions are electrically earthed to each other for safe operation.

Preferably, if the mechanical coupler assembly between carriages fails or is improperly connected and the towing forces between carriages is taken by the electrical coupler assembly, the coupler assembly should separate by shearing pins in the screw handles and/or retaining collars so that the connector separates with a minimum of damage.

Brief Description of the Drawings A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein: Figure 1 is a perspective view showing a first coupler sub-assembly of an embodiment of the invention; Figure 2 is a perspective view showing a second coupler sub-assembly of an embodiment of the invention; Figure 3 is a perspective view showing the coupler assembly of an embodiment of the invention from one direction; Figure 4 is a perspective view of Figure 3 from an alternate direction; [R:\LIBLL] 16928.doc:gxt -6- Figure 5 is a front view of the body of a coupler sub-assembly shown in Figures 1 to 4.

Detailed Description of the Preferred Embodiments In the accompanying drawings, there is schematically depicted an electrical rail coupler assembly 1 to maintain in use electrical contact between adjacent railway carriages while excluding all water. The assembly 1 includes a pair of complimentary sub-assemblies 5 securable together in use to maintain electrical contact and sealing engagement therebetween. Each electrical coupler sub-assembly 5 includes a base 10 to be fixed to a respective one of the carriages. A body 15 is attached to the base 10. The sub-assembly 5 also includes at least one electrical plug portion 25 to engage a complimentary electrical receptacle portion 26 of the other sub-assembly 5 so that the sub-assemblies 5 when secured together are electrically and sealingly corinected. The electrical portions 25, 26 are moved, into electrical contact engagement by relative movement, in a predetermined direction by at least one of the bodies 15 being movable in that direction relative to its associated base 10 to provide for engagement and disengagement of the electrical portions 25, 26. Securing means 30 extend between the bodies 15 to releasably secure the bodies 15 together with the electrical portions 25, 26 in electrical and sealing contact.

In the preferred form, both the bodies 15 are movable in the direction which is preferably normal to said base 10. At least one of the bodies 15 and preferably both include positioning means 35 to adjust the position of the bodies 15 relative to the respective base 10. The positioning means 35 includes a pin 37 extending through an aperture 39 in said body 15 and movable in the direction. The pin 37 being fixed to the [R:ALIBLL] 16928.doc:gxt base 10 as shown in the Figures. However, other positioning systems such as a pivot or hinge could be utilised.

As best seen in Figure 5, the body 15 also includes one or more apertures 40 to receive and secure corresponding electrical portions 25, 26 to the assembly 1.

In the preferred form, the assembly 1 can include more than one securing means including each a locking pin 45 which is threaded at one end and extendable normal to the bodies 15 for locking engagement with a complimentary aperture 50 located therein.

The locking pin 45 could include a handle 55 at one end so that a user does not require any tools to secure the sub-assembly 5 together. The handle 55 could. be pivoted as shown in the Figures or fixed.

The electrical portions 25, 26 are preferably sealed modules.

In use, two train carriages are mechanically coupled together and any dummy plates are removed from the electrical couplers. The couplers sub-assemblies 5 are slid together until the threaded ACME shafts or pins 45 are engaged in their corresponding sockets. The two threaded shafts 45 are turned in parallel by means of the hinged handles drawing the bodies or plates 15 together and progressively engaging the plug modules into the receptacle modules 26. Eventually, the ends of the plug and/or receptacle sleeves compress into rubber gaskets, rendering the entire connection waterproof against the ingress of external water or washing fluids.

The electrical rail coupler assembly 1 in a preferred embodiment includes a fully sealed module assembly where each module can be individually replaced if damaged.

One sub-assembly 5 would include the "male" fittings (see Figure 1) and in the preferred [R:\LIBLLJ 16928.doc:gxt form could be: one high tension module containing two 16mm diameter pins and one 14mm diameter pin; two AC modules, each containing three 16mm diameter phase pins and one 10mm direction neutral pin; and one pilot module containing sixteen 4mm diameter pins. The bodies 15 are preferably 24mm thick mild steel machined holding plates having two locking pins or clamping screws 45. The corresponding complimentary sub-assembly 5 would include the "female" fittings (see Figure 2) and include: one high tension module containing two 16mm diameter multi-wire sockets and one 14mm diameter multi-wire socket; two AC modules, each containing three 16mm diameter phase multi-wire sockets and one 10mm diameter neutral multi-wire socket; and one pilot lo module containing sixteen 4mm diameter multi-wire sockets. It should however be noted that it is possible to save some pins and sockets by emitting two contacts in the high tension modules. However, for simplicity and to reduce the number of different modules required for spare parts it is preferred to make all high tensioned modules the same. Also, the number of pins can change depending upon the requirements in use. As discussed above, the sub-assembly 5 will be clamped together in use by the securing means which can include a hardened steel guide pin 45 which will slide inside a corresponding bush or aperture 50 located in the adjacent body 15. If required there could be more than one securing means 30. The locking pins 45 should be ACME threaded and fitted with hinged handles 55. When the locking pins or screws 45 are wound the body 15 will come together until the ends of the base 10 come together. The base 10 can include rubber gaskets or the like as contact points. As locking pins or screws 45 provide a secure lock of the mechanical advantage to overcome the insertion pressure between the pins and sockets. Likewise, winding the locking pins or screws 45 in the opposite direction causes the body or plates 15 to separate to overcome the extraction force between the pins and [R:\LIBLL] 16928.doc:gxt -9sockets. The handle 55 is left loose so that it will hang down and not work loose with vibration.

The system could also include "dummy" plates for use whilst carriages are being serviced. The "dummy" plate will fit securely over each of the sub-assemblies 5. Though a preferred embodiment of the base 10 has been shown in the figures it should be understood that many different base structures could be used depending upon the particular train carriage.

In the preferred form, and to provide the necessary strength and corrosion resistance the following materials are presently proposed. Contact pins are silver plated 147 alloy grade copper with crimped connections for cable conductors; sockets are imported silver plated multi-wire sockets with crimped connections for cable conductors; resin is a two pack Kevlar-reinforced high strength resin; cylindrical module bodies are machined from solid 316 marine grade stainless steel tube bars or cast high tensile bronze and guide pins, sleeves and clamping screws are made from high strength steel. The guide pins would be case hardened for wear resistance; retaining plates or bodies would be machined from 24mm thick plate steel that would be zinc passivated for corrosion protection.

The electrical portions 25, 26 can also include a two pack epoxy resin containing Kevlar-filler for increased strength and resilience. The resin is non-toxic with superior crack resistance, impact strength and waterproof characteristics. The resin should have a dielectric constant making it suitable for isolating electrical phases in high voltage applications. It should chemically bond to cable sheath and conductor insulators ensuring there are no tensile stress concentrations at cable terminals. Further, the socket should be [R:\LIBLL] 16928.doc:gxt silver plated multiple-wire designed. This would give lower insertion and withdrawal forces and improve the electrical continuity even when mating pins are slightly eccentric.

Further, this minimises minor arcing and pitting on the surface of the socket as the size of the sockets is dictated by the cable cross sectional area that each can accommodate. For example, a 16mm diameter socket accommodating a 95mm 2 cable can carry a long term nominal current of 340 amps and a maximum current of 460 amps. Likewise, a 14mm socket attached to a 70 mm 2 cable can carry 280 and 400 amps respectively. The 10 mm neutral socket can accommodate 175 and 275 amps respectively. Finally, the size of the pilot sockets is dictated by our experience of the need for physical robustness rather than electrical capacity. A 4mm socket will carry 55 and 80 amps respectively.

Each module or electrical portion 25, 26 should be fully waterproofed, being permanently bonded to the cables and conduits. Even if the conduit itself fills with water no moisture would penetrate into the electrical connections with the electrical portion 26. When clamped together the male and female connectors are sealed against water penetration by heavy duty rubber gaskets 70. Further, in the preferred form the width of the assembly 1 would be approximately 363mm, the depth approximately 266mm and the length approximately 222mm. This is significantly smaller than existing systems which are typically 500mm by 350mm by 350mm. The estimated mass of each half connector would be between about 27 kilograms to 30 kilograms. This is also significantly in less than existing systems which are more than 40 kilograms.

Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

[R:\LIBLL] 16928.doc:gxt

Claims (17)

1. An electrical rail coupler assembly to maintain in use electrical contact between adjacent railway carriages; said assembly including a pair of complimentary coupler sub-assemblies securable together in use to maintain said electrical contact therebetween; each said coupler sub-assembly including: a base to be fixed to a respective one of said carriages; a body attached to the base; at least one electrical plug portion to engage an electrical receptacle portion of the other sub-assembly so that the sub-assemblies when secured together are electrically connected; and wherein the electrical portions are moved, into electrical contact engagement by relative movement, in a predetermined direction by at least one of the bodies being movable in said direction relative to its associated base to provide for engagement and disengagement of said plug and receptacle portions; and securing means extending between the bodies to releasably secure the bodies together with the plug and receptacle portions in electrical contact.

2. The electrical rail coupler assembly according to claim 1, wherein both said bodies are movable in said direction relative to their associated base.

3. The electrical rail coupler assembly according to claim 2, wherein at least one said body includes positioning means to adjust the position of said body relative to said base. [R:\LIBLL] 16928.doc:gxt -12-

4. The electrical rail coupler assembly according to claim 1, wherein said positioning means includes a pin extending through an aperture in said body and movable in said direction, said pin being fixed to said base.

The electrical rail coupler assembly according to any one of the preceding claims, wherein each said body includes an aperture to receive said electrical plug or receptacle portion.

6. The electrical rail coupler assembly according to claim 5, wherein each said body includes a plurality of apertures for receipt of a plurality of electrical plug or receptacle portions.

7. The electrical rail coupler assembly according to any one of the preceding claims, wherein said securing means includes a locking pin extending normal from one said body for locking engagement with a complimentary aperture located in said other body.

8. The electrical rail coupler assembly according to claim 7, wherein said locking pin includes a threaded portion.

9. The electrical rail coupler assembly according to claim 7 or 8, wherein said locking pin includes a handle.

The electrical rail coupler assembly according to any one of the preceding claims, wherein each said electrical plug or receptacle portion is a sealed module. [R:\LIBLL]I 6928.doc:gxt -13-

11. The electrical rail coupler assembly according to any one of the preceding claims, wherein when said electrical plug and receptacle portions are in electrical contact engagement, the plug and receptacle portions are also in sealing engagement.

12. The electrical rail coupler assembly according to any one of the preceding claims, wherein each said electrical plug and receptacle portion includes a means of keying the plug and receptacle portion, so that the corresponding plug and receptacle portions are, in use, always mated.

13. The electrical rail coupler assembly according to any one of the preceding claims, wherein each plug and receptacle portion is individually removable and replacable without disturbing other plug and receptacle portions.

'14. The electrical rail coupler assembly according to any one of the preceding claims, wherein all plug and receptacle portions are electrically earthed to the body for safe operation.

15. The electrical rail coupler assembly according to any one of claims 1 to 13, wherein all plug and receptacle portions are electrically earthed to each other for safe operation.

16. The electrical rail coupler according to claim 1, whereby if the mechanical coupler assembly between carriages fails or is improperly connected and the towing forces between carriages is taken by the electrical coupler assembly, the coupler assembly should separate by shearing pins in the screw handles and/or retaining collars so that the connector separates with a minimum of damage. [R:\LIBLL] 16928.doc:gxt -14-

17. An electrical rail coupler assembly, substantially as herein described with reference to any one of the embodiments of the invention shown in Figures 1 to Dated 6 September, 2005 New Macey Pty Limited Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON [R:\LIBLL] 16928.doc:gxt