MOTORIZED TROLLEY

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims benefit, under 35 U.S.C. § 119(e), of U.S. provisional patent application Ser. No. 63/670,439, filed on Jul. 12, 2024, which is incorporated herein in its entirety by reference.

TECHNICAL FIELD

The present invention relates to a trolley, more particularly, to a guided motorized trolley.

BACKGROUND

Trolleys, when attached to a guide such as a zipline, cable, or rail, enable a person or cargo to traverse along a path over a distance. Guided trolleys are typically used in both recreational and industrial applications. Guided trolleys may consist of a body that houses sheaves running along a guide, such as zipline trolleys, or a body fixed to a hauling cable that moves over supporting sheaves, such as in cable cars or aerial tramways.

In some cases, the trolley may be accelerated by gravity, allowing the rider or cargo to navigate down a slope. The sheaves minimize friction, allowing for a controlled and often high-speed descent. At the end of the guide, a braking mechanism such as friction pads, springs, or magnetic brakes may slow down and eventually stop the trolley. These mechanisms are designed to absorb kinetic energy and bring the trolley to a safe halt.

To return the trolley to the start position, manual rewinding methods such as hand-cranked winches or pull-back ropes may be used. These require physical effort but are effective for shorter distances. Some ziplines may instead use a counterweight system, where a weight is attached to a pulley system on the opposite end of the zipline. As the trolley moves down, the counterweight is lifted, storing potential energy. When the trolley needs to be rewound, this energy is released, pulling the trolley back up. In industrial or commercial setups, motorized winches may be employed. The winches may be connected to the trolley via a cable or rope. Once the descent is complete, the winch is activated, pulling the trolley back up the incline.

However, after completing a zipline descent, the user is typically at the lower end of the zipline. If the controls for rewinding the motorized trolley are located uphill, the user must navigate back uphill to access them. This can be impractical, especially in remote or rugged terrains where physical access is difficult and time-consuming. When the controls are mounted on the trolley itself, they may be high above the ground, making them difficult to reach for the user standing at the lower end of the zipline. While remote controls may provide a solution to the accessibility issue, they are small and easily misplaced or lost, especially in outdoor environments.

The location of controls for motorized trolleys presents challenges in terms of accessibility, safety, and operational efficiency. The disclosure presented herein may address some of these challenges.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

In a first aspect, the technique described herein relates to a motorized trolley comprising a traction wheel positionable over a guiding structure, an assisting motor connected to the traction wheel via a clutch, a speed sensor measuring a rotational speed of the traction wheel and a motor controller electrically attached to the assisting motor and the speed sensor. Optionally, the guiding structure may be a zipline cable.

In embodiments, the traction wheel may be a sheave pulley, and the guiding structure may be a zipline cable.

In embodiments, the clutch may be a clutch bearing located inside traction wheels. Alternatively, the assisting motor may comprise a rotor and the clutch may be a clutch bearing located inside the rotor. Optionally, the clutch may be configured to engageably-disengage the assisting motor and the traction wheel when the rotational speed exceeds a maximum motor speed.

In embodiment, the motor controller may engage the assisting motor when the motorized trolley accelerates along the guiding structure beyond an activation speed. The motor controller may further disengage the assisting motor when the motorized trolley decelerates along the guiding structure below the activation speed. In embodiment, the activation speed may be at least 7 km/h.

In embodiment, the motor controller may disengage the assisting motor when the motorized trolley accelerates along the guiding structure beyond a maximum speed. The motor controller may further re-engage the assisting motor when the motorized trolley decelerates along the guiding structure below the maximum speed. In embodiment, the maximum speed may be at least 35 km/h.

In embodiments, the motorized trolley may further include a power source electrically connected to the motor controller. The power source may include at least one power-tool battery.

In embodiments, the motorized trolley may further include a manual safety trigger configured to activate the assisting motor at a reduced speed in case of a system failure.

In a second aspect, the technique described herein relates to a method for operating a motorized trolley. The method may include engaging an assisting motor when the motorized trolley accelerates along a guiding structure beyond an activation speed and disengaging the assisting motor when the motorized trolley decelerates along the guiding structure below the activation speed. In embodiment, the activation speed may be at least 7 km/h.

In embodiments, the guiding structure may be a zipline cable.

In embodiments, the assisting motor may be disengaged when the motorized trolley accelerates along the guiding structure beyond a maximum speed, and the assisting motor may be re-engaged when the motorized trolley decelerates along the guiding structure below the maximum speed. In embodiment, the maximum speed may be at least 35 km/h.

In embodiments, the assisting motor may be engaged at a reduced speed upon activating a safety trigger and disengaged upon deactivating the safety trigger.

In a third aspect, the technique described herein relates to a non-transitory computer-readable medium storing a set of instructions for operating a motorized trolley. The set of instructions may include one or more instructions that, when executed by one or more processors of a device, cause the device to engage an assisting motor when the motorized trolley accelerates along a guiding structure beyond an activation speed, and disengage the assisting motor when the motorized trolley decelerates along the guiding structure below the activation speed. In embodiment, the activation speed may be at least 7 km/h.

In embodiments, the guiding structure may be a zipline cable.

In embodiments, the assisting motor may be disengaged when the motorized trolley accelerates along the guiding structure beyond a maximum speed and re-engaged when the motorized trolley decelerates along the guiding structure below the maximum speed. In embodiment, the maximum speed may be at least 35 km/h.

In embodiments, the assisting motor may be engaged at a reduced speed upon activating a safety trigger and disengaged upon deactivating the safety trigger.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and exemplary advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the appended drawings, in which:

FIG. 1 is a drawing depicting a side view of an exemplary embodiment of a motorized trolley in accordance with the teachings of the present invention;

FIG. 2 is a drawing depicting a front view of an exemplary embodiment of a motorized trolley in accordance with the teachings of the present invention;

FIG. 3 is a drawing depicting a top view of an exemplary embodiment of a motorized trolley in accordance with the teachings of the present invention;

FIG. 4 is a drawing depicting a perspective view of an exemplary embodiment of a motorized trolley in accordance with the teachings of the present invention;

FIG. 5 is a drawing depicting a lateral cross section of an exemplary embodiment of a motorized trolley in accordance with the teachings of the present invention;

FIG. 6 is a logical modular representation of an exemplary embodiment of a motorized trolley in accordance with the teachings of the present invention;

FIG. 7 is a nodal operation and flow chart of an exemplary method for operating a motorized trolley in accordance with the teachings of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

When motorized, some zip line trolleys may be activated using a remote or a manual switch in order to rewind the zip line to its alternative location or assist with the transport of the trolley's payload. In some cases, the remote or the switch may be located uphill while the trolley is downhill, or vice versa. When operating the trolley with a wired switch, the location of the switch may be impractical or difficult to reach. When operating the trolley with a wireless remote, the remote may become out of range or easily misplaced or lost, especially in outdoor environments. There is a need to simplify the operation of a motorized trolley.

Reference is now made to the drawings in which FIG. 1 depicts a side view of an exemplary embodiment of a motorized trolley 100 in accordance with the teachings of the present invention. FIG. 2 is an exemplary drawing depicting a front view of an exemplary embodiment of the motorized trolley 100. FIG. 3 is an exemplary drawing depicting a top view of an exemplary embodiment of a motorized trolley 100. FIG. 4 is an exemplary drawing depicting a perspective view of an exemplary embodiment of a motorized trolley 100. FIG. 5 is an exemplary drawing depicting a lateral cross section of an exemplary embodiment of a motorized trolley 100. FIG. 6 is a logical modular representation of an exemplary embodiment of a motorized trolley 100. FIG. 7 is a nodal operation and flow chart of an exemplary method for operating a motorized trolley 100.

A first aspect of the teachings presented herein relates to a motorized trolley 100 comprising a traction wheel 110 positionable over a guiding structure 50, an assisting motor 120 connected to the traction wheel 110 via a clutch 130, a speed sensor 140 measuring a rotational speed of the traction wheel 110 and a motor controller 150 electrically attached to the assisting motor 120 and the speed sensor 140. Together, the guiding structure 50 and the motorized trolley 100 may be considered as a motorized trolley system 1000.

The motorized trolley 100 may, for example, be used in a variety of recreational, industrial and specialized applications. Recreational uses may include, for example, zipline tours including thrill rides and scenic tours, or sports and training, including obstacle courses and recreational sports. Industrial applications may include, for example, transport of material for construction sites or forestry, maintenance and inspection of large structures such as bridges, dams, and towers or utility lines, enabling access to elevated areas for maintenance and repairs. Industrial uses may also include emergency and rescue operations such as facilitating rapid transport of rescue personnel and equipment in challenging environments such as mountainous or flood-affected areas or providing an efficient means of evacuating individuals from remote or inaccessible locations during emergencies. Specialized applications may include crop monitoring, deployment of pest control measures across extensive farming areas. Other specialized applications may include allowing researchers to traverse and monitor wildlife habitats without causing significant disturbance or facilitating access to study and collect data from ecosystems that are otherwise difficult to reach. Other specialized applications may include providing unique angles and perspectives for capturing footage in natural or urban environments for film and photography or facilitating the transport of equipment in events, particularly in outdoor or large-scale venues.

Broadly, a motorized trolley may provide rapid movement from one point to another, especially in environments where traditional forms of transportation are impractical or slow. Motorized trolleys may provide access to remote, rugged, or elevated areas that might otherwise be challenging to reach, such as dense forests, mountains, or construction sites. Ziplines may provide a thrilling experience, allowing users to glide through the air at high speeds, often with scenic views. Users may enjoy unique aerial views of landscapes, offering a perspective that may not be possible from the ground.

In situations where the zipline provides a slope and the motorized trolley is navigating downward, gravity may reduce the need for significant physical exertion from the user. When the downward slope is not sufficient to reach practical speeds, the assisting motor 120 may provide assistance to reach higher speed. In situations where the zipline is horizontal or even upward, the motion of the motorized trolley may rely entirely on the assisting motor 120.

The assisting motor 120 may aid in propelling the trolley along the guiding structure. The assisting motor 120 motor can engage and provide additional force to move the trolley, particularly useful for returning the trolley to the start position or for maintaining controlled speeds during descent. To be effective in a motorized trolley, especially when dealing with varying speeds and weights, including uphill travel, the assisting motor should possess several key characteristics:

The specific configuration of the assisting motor 120 may depend on many factors including power output, support for variable speed control and smooth transitions in speed, energy efficiency, heat management, durability and reliability, robustness to mechanical stress, continuous use, exposure to outdoor conditions including moisture, dust, and temperature variations, maintenance requirements, compatibility with the motor controller 150, safety features, power source compatibility, weight and size, and weather resistance. The assisting motor 120 may comprise a transmission such as gears or belts in order to reduce the rotational speed of the rotor and increase torque.

For example, the assisting motor 120 may be a 500 W/6000 RPM brushless DC motor. When powered by two 18 V power tool batteries, each providing 20 A, the trolley may be capable of pulling a weight of 80 kg up a 30% incline at about 8 km/h using a gear reduction ratio of 7:1. In other scenarios, when the 500 W/6000 RPM brushless DC motor is used without reduction to rewind a trolley with no payload (apart from its own weight), speeds above 35 km/h may be achieved on a horizontal or 10% decline.

The traction wheel 110 may be a wheel that is designed to grip and move along a surface such as the zipline cable such as a sheave pulley. The traction wheel is responsible for driving the movement of the motorized trolley along the cable. The traction wheel may use rubber-coated metal, polyurethane, steel or other metals or materials. The traction wheel may be of different diameters depending on the specific purpose and use. For example, compact trolleys may use a smaller (ex. 5-10 cm) traction wheel while industrial application applications may use a larger wheel (ex. 20-30 cm) for enhanced stability and larger payloads.

The guiding structure 50 may be a zipline cable such as a strong, flexible wire rope or cable that is suspended between two points, typically but not necessarily on a downward slope, allowing a trolley to traverse it under the influence of gravity or motorized propulsion. The zipline cable 50 may be made of galvanized steel, stainless steel, synthetic rope or other suitable material. The zipline cable 50 diameter may be smaller for light payloads (ex. 6-8 mm) or larger for heavier payloads (ex. 14-16 mm) or any other diameter suitable to safely support the expected payload and support the appropriate cable tension.

In embodiments, the clutch 130 may be a clutch bearing located inside traction wheel 110. The clutch bearing 130 may allow the motor to engage with the traction wheel when power is needed, such as when the trolley needs to move or accelerate along the guide structure. The clutch bearing 130 may disengage the motor from the traction wheel when the trolley is coasting or when it exceeds certain speeds to prevent overloading or overheating the motor.

Optionally, the clutch 130 may be configured to engageably-disengage the assisting motor 120 and the traction wheel 110 when the rotational speed exceeds a maximum motor speed. The clutch bearing 130 may also disengage the motor when the speed of the trolley speed exceeds a predefined maximum speed in order to maintain safe operational speeds and prevents mechanical damage due to excessive speeds. The clutch bearing 130 may re-engage once the speed drops below the maximum threshold, ensuring continuous operation without manual intervention. The clutch bearing 130 may protect the motor by disengaging it during instances of high rotational speed or excessive load, thereby preventing potential damage to the motor and other components. By disengaging the motor when it is not needed (e.g., during coasting), the clutch bearing may also reduce unnecessary mechanical stress and wear on the motor, extending its operational life. Disengaging the motor when it's not required may also conserve energy. In case of system failures, the clutch bearing may provide a fail-safe by disengaging the motor, preventing uncontrolled movements of the trolley. Alternatively, in embodiments, the clutch bearing 130 may engage the motor in coasting scenarios for assisted braking or energy regenerating scenarios. In case of system failure, the clutch bearing may engage the motor at a reduced speed using the manual safety trigger, providing a controlled and safe operation mode.

Different types of clutch bearing 130 may be used, such as, for example, a sprag clutch, a centrifugal clutch or an electromagnetic clutch. One-way clutch bearings (such as sprag clutch or roller clutch) may allow rotation in one direction and lock in the opposite direction and may be useful in scenarios where the motor should only be engaged when travelling in one direction. Centrifugal clutch bearings may be a preferred choice for engaging and disengaging the motor when a maximum rotational speed is exceeded. An electromagnetic clutch may be used for more complex scenarios, when, for example, the motor needs to be disengaged at different speed thresholds such as under a minimum speed threshold and a maximum speed threshold.

The clutch bearing 130 may be integrated within the traction wheel in order to achieve a more compact and possibly lighter trolley design. Additionally, by integrating the clutch within the traction wheel, the clutch may be protected from external elements such as dirt, moisture, and debris. A direct integration of the clutch within the traction wheel may also reduce mechanical losses associated with power transmission and may improve the efficiency of the system.

Alternatively, the assisting motor 120 may comprise a rotor and the clutch 130 may be a clutch bearing located inside the rotor. When integrating the clutch bearing within the motor, controls of the trolley may be centralized without compromising compactness.

Alternatively, the clutch may be positioned externally between the motor and the traction wheel, connected via a drive shaft or belt. A clutch bearing integrated to an external drive shaft or belt may provide easier access for maintenance.

In other embodiments, a disengageable gear system may be used to engage or disengage the motor from the traction wheel.

The method for operating a motorized trolley 100 may include engaging 230 an assisting motor 120 when the motorized trolley 100 accelerates along a guiding structure 50 beyond an activation speed. For example, the trolley may be manually accelerated beyond the activation speed (e.g., by being pushed or pulled). Upon reaching the activation speed, the motor may automatically engage the traction wheel to further accelerate the trolley. Persons skilled in the art will readily understand that the exact activation speed may depend on the purpose of the trolley. Transport of heavy payloads may, for example, be carried out at low speed and the activation speed may be 2-4 km/h while lightweight payloads may be transported at faster speed and use a higher activation speed of 5-10 km/h. When the initial propelling is achieved by pushing or pulling using the arms of a user, lower activation speed may be used, while higher activation speeds may be used when the user provides the initial acceleration by running along the trolley. Broadly, the activation speed should be high enough so that it is not triggered accidentally, and low enough such that it may be achieved with reasonable effort from a user. When the trolley is being accelerated by other means than a user, such as by gravity, the activation speed should be high enough to distinguish between states when the payload is being prepared for transport and states when the payload is traveling.

In embodiment, the activation speed may be at least 7 km/h. A speed of 7 km/h may represent a speed at which an average adult is transitioning from fast walking to jogging. In the context of a zipline trolley, for example, 7 km/h may indicate that the user is no longer walking (i.e., preparing for transport) and instead chooses to travel along the zipline. In the context of a zipline trolley, 7 km/h may also indicate that the trolley is being accelerated by gravity, meaning that it has left the platform.

The method for operating a motorized trolley 100 may further include disengaging 220 the assisting motor 120 when the motorized trolley 100 decelerates along the guiding structure 50 below the activation speed. In embodiment, the activation speed may be at least 7 km/h. Decelerating below the activation speed may indicate that the user is pulling back on the trolley with the intention of slowing it down or bringing it to a halt. Decelerating below the activation speed may also indicate that an external braking system is interfering with the motion of the trolley and suggest that the trolley should be slowed down or halted.

In embodiment, the motor controller 150 may disengage 240 the assisting motor 120 when the motorized trolley 100 accelerates along the guiding structure 50 beyond a maximum speed. Disengaging the assisting motor 120 may be necessary to comply with safety regulations or to prevent damage to the assisting motor 120. For example, when the trolley is being accelerated by an external force such as gravity or another device running along the guide, the assisting motor 120 may disengage.

The motor controller 150 may further re-engage 230 the assisting motor 120 when the motorized trolley 100 decelerates along the guiding structure 50 below the maximum speed. For example, when being accelerated by gravity, the slow may change such that the gravity pull is no longer sufficient to overcome friction and maintain the maximum speed.

Persons skilled in the art will readily understand that the maximum speed may depend on the purpose of the pulley. Heavier payload may for example be configured to travel at lower maximum speed, while lighter payload may be configured to travel at higher maximum speeds. In embodiment, the maximum speed may be at least 35 km/h. In the context of a zipline trolley, for example, 35 km/h may correspond to a speed at which the user experience is enjoyable without feeling unsafe. 35 km/h may also correspond to a maximum speed at which the assisting motor 120 may safely be operated.

Powering the motorized trolley 100 using a direct connection to an external power grid is possible but may be inconvenient in some scenarios.

In embodiments, the motorized trolley 100 may further include a power source 170 electrically connected to the motor controller 150. The power source may supply electrical energy to the motor controller, which in turn powers the assisting motor and other electronic components of the trolley. The power source may allow the motorized trolley to operate independently without the need for external power supply infrastructure. The power source may consist of rechargeable batteries, such as lithium-ion (Li-ion) batteries or nickel-metal hydride (NiMH) batteries or alkaline batteries. Alternatively, or additionally, the power source may include capacitors or supercapacitors. In other embodiments, in particular when charging facilities are not accessible, hydrogen fuel cells or other types of fuel cells may be used to provide a continuous supply of electricity as long as fuel is available. The power source may be directly wired to the motor controller. For rechargeable batteries, a battery management system (BMS) may be included to monitor and manage the charging and discharging cycles, ensuring the safety and longevity of the batteries.

The power source 170 may include at least one power-tool battery. Power-tool batteries may be widely available and may be easily sourced from various manufacturers, making them a convenient option for powering the motorized trolley. Power-tool batteries may be designed to be interchangeable across different tools from the same manufacturer, which means users may already have compatible batteries on hand that may be used for the trolley. Power-tool batteries, such as modern lithium-ion (Li-ion) types may offer high energy density, providing substantial power in a compact form factor. Power-tool batteries may also be built to withstand tough conditions, including shock, vibration, and temperature extremes, making them suitable for the potentially rugged environments in which the motorized trolley might operate. Power-tool battery packages may also be designed for frequent swapping, minimizing downtime and enhancing operational efficiency. Examples of power-tools that may be used include the DeWalt 20V MAX XR Lithium-Ion Battery, the Makita 18V LXT Lithium-Ion Battery, the Bosch 12V NIMH Battery Pack and the Milwaukee 14.4V NiCd Battery.

In embodiments, the assisting motor 120 may be engaged at a reduced speed upon activating a safety trigger 160 and disengaged upon deactivating the safety trigger 160. The manual safety trigger 160 may be configured to activate the assisting motor 120 at a reduced speed in case of a system failure. Manual control may be useful, for example, when the payload is immobilized along the guide and unable to achieve the activation speed. In the context of a zipline trolley, a user may be immobilized along the zipline when the inclined is not steep enough to provide acceleration. Using the manual safety trigger 160, the trolley may be accelerated without having to reach the activation speed in order to reach the platform.

In embodiments, the trolley may be activated or deactivated using a non-transitory computer-readable medium storing a set of instructions for operating a motorized trolley 100. The set of instructions may include one or more instructions that, when executed by one or more processors of a device, cause the device to engage 230 the assisting motor 120 and disengage 220 the assisting motor 120 as discussed hereinabove.

When enabled 242, the processor may, for example, evaluate 210 the speed of the trolley from a connected sensor. Upon detecting that the speed of the trolley is below the activation speed 212, the processor may disengage 220 the assisting motor. Upon detecting that the speed of the trolley is within the activation speed and the maximum 214, the processor may engage 230 the assisting motor. Upon detecting that the speed of the trolley is above the maximum speed 216, the processor may disengage the 240 the assisting motor. The speed may continue to be monitored as long as the instructions are enabled 250 on the motorized trolley 100.